Components molded with moldable carbon fiber and methods of manufacturing thereof
AssigneeGM Global Technology Operations LLC
InventorsHamid G. Kia, Selina X. Zhao
Life of this patent
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Abstract
In various aspects, the present disclosure provides a structural component. The structural component includes a body defining at least one hollow region. The body includes a carbon fiber composite including a plurality of substantially aligned continuous carbon fibers. The plurality of substantially aligned carbon fibers defines a major axis and a second axis perpendicular to the major axis. The plurality of substantially aligned continuous carbon fibers includes a plurality of discrete termination points staggered with respect to the second axis. Methods of making such structural components, including by blow molding and compression molding are also provided.
Claims20
A structural component comprising:
- a body defining at least one hollow region, wherein the body comprises a carbon fiber composite comprising a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis, wherein the plurality of substantially aligned continuous carbon fibers comprises one or more continuous carbon fibers having a length of greater than or equal to about 2 inches, wherein the one or more continuous carbon fibers comprise a plurality of discrete weak regions along the length of the one or more continuous carbon fibers, wherein the plurality of discrete weak regions comprise a composition that has an ultimate tensile strength that is at least 50% less than the ultimate tensile strength of the remainder of the length of the one or more continuous carbon fibers.
A structural component comprising:
- a body defining at least one hollow region, wherein the body comprises a carbon fiber composite comprising a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis, wherein the plurality of substantially aligned continuous carbon fibers comprises one or more continuous carbon fibers having a length of greater than or equal to about 2 inches, wherein the one or more continuous carbon fibers comprise a plurality of discrete weak regions along the length of the one or more continuous carbon fibers, wherein the plurality of discrete weak regions comprise a composition that has an ultimate tensile strength that is at least 50% less than the ultimate tensile strength of the remainder of the length of the one or more continuous carbon fibers, and the carbon fiber composite has an ultimate tensile strength of greater than or equal to about 500 MPa.
A method of producing a structural component having at least one interior cavity, the method comprising:
- placing a parison comprising a moldable carbon fiber precursor material disposed around a mandrel in a die, wherein the moldable carbon fiber precursor material comprises a polymer precursor and a plurality of substantially aligned continuous carbon fibers defining a major axis and a second axis perpendicular to the major axis, wherein the plurality of substantially aligned continuous carbon fibers comprise a plurality of discrete termination points staggered with respect to the second axis, wherein the plurality of substantially aligned continuous carbon fibers comprises one or more continuous carbon fibers having a length of greater than or equal to about 2 inches, wherein the one or more continuous carbon fibers comprise a plurality of discrete weak regions along the length of the one or more continuous carbon fibers, wherein the plurality of discrete weak regions comprise a composition that has an ultimate tensile strength that is at least 50% less than the ultimate tensile strength of the remainder of the length of the one or more continuous carbon fibers;
- blow molding the parison to create the structural component;
- and
- crosslinking or solidifying the polymer precursor to form the structural component.
Dependencies are inferred from the claim text.